Terminal



' Gttorneg H V KNAUF JR ETAL TERMINAL Flled Oct 31 1940 Nov. 1o, 19412.

Patented Nov. 10, 1942 g TERMIN A-L Harry V. Knauf, Jr., Oaklyn, andCharles Scheer, Haddoneld, N. J., assignors to Radio Corporation ofAmerica, a corporation of Dela- Ware Application October 31, 1940,Serial No. 363,792

1 Claim.

This invention relates to electrical terminals, and more particularly toterminal banks or boards wherein the conductive terminal elements areaflixed in spaced relation to an insulating base; and to methods ofmaking and assembling the same.

In accordance with the standard practice of axing terminal elements orblanks to an insulating strip, sheet, board or other base, theinsulating material is rst punched to provide holes for the reception ofthe base portions of the terminals which are then crimped or otherwiseanchored to the surrounding surface or surfaces of the insulatingmaterials.

The standard practice above described is objectionable (a) becauseebonite and the common synthetic resinous materials of which the stripsare usually formed may be, and frequently are, shattered during thepunching operation; (b) because the force employed in the crimpingoperation may crack the surfaces to which the bases of the terminals areaffixed, and (c) because even where D-shaped (instead of circular) holesare provided, a permanently rigid connection is not ensured merely bybending the base of a terminal over the surrounding surface of theinsulating material. v

Accordingly, an object of the present invention is to provide a terminalstrip, or other insulating base, wherein the terminal elements aremaintained in permanent rigid relation, and one which lends itselfreadily to mass production methods.

Another and important object of the invention is to provide a simple,inexpensive, trouble-free method of making terminal strips and the like,and one which, in its practice, alfords a minimum number of nonusableunits.

In the drawing:

Figures 1 and 2 are views in perspective of preformed terminal blanks ofdifferent patterns which may be employed in carrying the invention intoeifect,

Figure .3 is a plan view of a completed terminal strip embodying theinvention and incorporating the blanks of Figs. 1 and 2,

Figure 4 is a sectional view taken on the line 4 4 of Fig. 3, and

Figure 5 is a sectional view taken on the line 5 5 of Fig. 2.

Like reference characters designate the same or corresponding parts inall figures.

The foregoing and other objects are simply achieved in accordance withthe invention by aixing the terminal elements or blanks T to aninsulating strip S, or the like, as by a stapling operation while theinsulating material is in a relatively soft or plastic condition.

Each terminal element T is preferably provided With one or morerelatively sharp prongs p to facilitate entry into the relatively softbase material and with a tongue e (Fig. 1) which may be bent over asurface or over an edge of the base S, subsequent to the staplingoperation, to lend added rigidity to the structure. As shown in Fig. 1,the prongs p may be located at the base or end of the terminal, or, asshown in Fig. 2, they may be conveniently located on opposite sides ofthe terminal intermediate its ends in the event that it is desired toutilize the end of the terminal as a mounting lug or bracket b. In Fig.l the terminal T is shown at a moment when the prongs p have been driventhrough the base S, but prior to being bent into intimate contact withthe surface thereof.

When the insulating base or strip S comprises a thermo-setting compound,such, for example, as Bakelite, the prongs p of each terminal element Tare preferably driven through the strip, and the prongs p and tongue ebent over the strip, prior to settingf curing or polymerizing it.

Similarly, when the insulating material S comprises a solid or alaminated brous material (e. g., paper or fabric) impregnated with aphenolic or other synthetic resinous material, the terminals T arepreferably attached to the insulator S when it is in a semi-cured state,and its polymerization subsequently completed with the prongs p andtongue e of the said metal parts in place.

If, on the other hand, the insulating base S comprises a thermo-plastic(as distinguished from -thermosetting) material, the stapling of theprongs p and the crimping or bending of the prongs p and tongues e maybe carried out either before the material has been hardened (by drivingout the solvents usually present during the molding operation) in thefirst instance, or by resoftening it with heat immediately before thestapling operation.

Since, in any event, the insulating base material S is in a relativelysoft condition at the time the terminals and other metal parts areaflixed thereto, the said materials cannot shatter or crack during thestapling and crimping operations. Further, the tendency of the saidmaterials to iiow in setting, or to cold flow subsequent to setting,ensures an intimate, rigid and permanent bond between the base materialand the parts affixed thereto.

It is not deemed necessary to a complete disclosure of the invention toillustrate a device for performing the stapling and bending operationssince the prior art is replete With devices capable of handling staplesof various types. Neither is the invention limited in its usefulapplication to the particular shape or pattern of conductors or theattachment portions thereof shown in the drawing, since the disclosurein this respect is merely illustrative for purposes of explaining theinventive concept.

What is claimed is:

Method of making a terminal board from a pre-formed base constituted ofa synthetic resinous material, said method comprising semicuring saidpre-formed base, driving the prongs of a pronged metal connector throughsaid preformed base, bending the projecting portion of said prongs intointimate contact with said semicured synthetic resinous material, andsubsel0 quently completing its cure.

HARRY V. KNAUF, JR. CHARLES L. SCHEER.

